vapour101

Vapour box v2.0 designed by: Stephen Parker

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Stephen Parker

Unique vv/vw sub ohm box with LCD display

Brief description of design

This design will be completely unique as i have noticed a lot of people want something different from everyone else, the following design will include a process called swirl painting giving every box unique styles and patterns no box will be the same looking. I have also asked a lot of people what they like to see on their cigarettes and a lot of them have said they would like a screen display on their device to show the voltage and wattage as well as battery level of the device, i have sourced a DNA chip capable of doing these exact things and more such as manually override the watts from 7watts to 30watts so users can set there device to their required needs this chip also features a lock so you can lock the device and not worry about the device heating up in your pocket. Another thing i noticed a lot of people like is and adjustable atomiser connector, which this device will have. There will be fuses installed into the device as a safety feature to protect the batteries from too high amp loads. There will also be a Clear Polycarbonate window added to the device to give this device a professional look and finish.

Parts required for design – with parts info

DNA 30D board with LED screen/chip & micro USB charging board £23.79

DNA 30D 30Watt variable power module with OLED display The DNA30Dis a power regulated digital switch-mode DC-DC converter for personal vaporizers. It features a small OLED display, analogue or digital user controls, onboard buttons and synchronous rectification for maximum battery life and minimal heat generation.

http://www.ebay.co.uk/itm/Replacement-Board-LED-Micro-USB-Wall-Charger-DNA-30-Mod-Chip-7W-30W-DIY-/281435881125?pt=LH_DefaultDomain_3&hash=item4186e2bea5

Hammond 1590ABK box - £3.56 – to mount everything inside Body Colour: Black Enclosure Material: Aluminium Alloy Enclosure Type: Instrument External Depth - Metric: 31mm External Height - Metric: 93mm External Width - Metric: 27mm

IP Rating: IP54 NEMA Rating: 12K SVHC: No SVHC (16-Jun-2014)http://uk.mouser.com/ProductDetail/Hammond-Manufacturing/1590ABK/?qs=4dK74SdgGtwN7aPBfm0Hzg%3D%3D

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510 connector - £1.95 – to mount any atomiser onto the box.

Dedicated Bottom-Feeder 510s based on the proven V4 design. Comes with food grade stainless steel centre post with a 1.75mm hole for a generous juice flow. Tail is extended to 12mm (9mm usable) for easier tube deployment. Also included is a brass solder sleeve since it is a

pain to solder to stainless steel. Pry it open to on the gap tighten to tighten and solder to secure. (It is recommended that the lead wire be soldered first on the 2mm hole of the solder sleeve.)http://www.fatdaddyvapes.com/shop.html

battries - £10.50 – these will be wired in parallel to achieve a total of 2400mAh

The item is a professional and practical 3.7V rechargeable Li-po battery, which is suitable for Walkera 5G4Q3 5#10, GYRO Hercules Unbreakable RC Helicopter ZX-35850, or can be widely used on R/C Mini car, truck, boat helicopter, airplane...etc. It features 1200mAh high capacity with the continuous discharge rate up to 25C, then you need a LiPo balance charger is required to charge this battery.Specification- Battery size: 7cm*3.2cm*0.6cm (L*W*H)- Colour: as shown in the pictures.- Material: Lithium polymer.- Plug-type: JST plug.

- 100% brand new and high quality 3.7V 1200mAh 25C Rechargeable Lipo Battery.- Voltage: 3.7V.- Capacity: 1200mAh.- Maxi continuous discharge rate: 25C.- Working temperature: 0°C~45°C (charger); -20°C~60°C (discharger).http://www.ebay.co.uk/itm/2Pcs-3-7V-1200mAh-25C-Lipo-Battery-For-Walkera-5G4Q3-5-10-Syma-S006G-MJX-R-C-F29-/391180036239?pt=LH_DefaultDomain_3&hash=item5b1425a88f

4x Fuse £0.16 - for amp load safety Hold Current: 3 A Trip Current: 5.1 A Current Rating - Max: 100 A

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Maximum Voltage: 16 VDC Resistance: 97.5 mOhms Termination Style: Radial Series: USBR Operating Temperature Range: - 40 C to + 85 C Lead Spacing: 5.1 mm Dimensions: 11 mm L x 7.1 mm W x 3 mm H Type: PolyFuse Resettable PTChttp://uk.mouser.com/ProductDetail/Littelfuse/16R300GU/?qs=ZSIFh4sPSRouCQaFuDECOQ%3D%3D

Tactile Switches £0.47 - for toggle switches (mainly wattage up and down buttons)Operating Force: 2.9 N Brand: C&K Components Actuator: Dome Current Rating: 50 mA Voltage Rating DC: 32 VDC Power Rating: 0.2 VA Ground Terminal: No

Contact Form: SPST Switch Function: OFF - (ON) Termination Style: solder Pin Mounting Style: Through Hole Mounting Direction: Right Angle IP Rating: IP 60 Contact Plating: Silver Series: KSJ Factory Pack Quantity: 250 Travel: 1.2 mm Part # Aliases: LFT Y33A431N5FP Y33A431N5FPLFThttp://uk.mouser.com/ProductDetail/CK-Components/KSJ0M43180SHLFT/?qs=8LLMQjkBYsIQvOYeECRfXQ%3D%3D

20 Guage Red & Black wire £15.28 (£0.61 per foot) – to connect all the connections together(25 ft long wire) 20 gauge recommended for use with the chosen chiphttp://www.ebay.co.uk/itm/20Guage-25-Ft-12Vdc-Wire-Red-Black-2-Conductor-/311298886574?pt=LH_DefaultDomain_3&hash=item487adc0bae

Soldering iron £6.99 – to solder the wires into place

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30W-240 Iron Brand: MarksmanBritish standard plugHas a neat nib to ensure accurate distribution of the solder. http://www.ebay.co.uk/itm/30W-60W-ELECTRIC-SOLDERING-IRON-KIT-SOLDER-GUN-KIT-DESOLDER-LEAD-WIRE-PUMP-BNIB-/111476586964?_trksid=p2141725.m3641.l6368

Solder £1.89

20G TUBE OF SOLDER60/40 TIN/LEADFlux-coveredFor electrical and electronic work http://www.ebay.co.uk/itm/20G-TUBE-60-40-TIN-LEAD-SOLDER-WIRE-FLUX-COVERED-ELECTRICAL-SOLDERING-DIY-HOBBY-/181452656168?pt=LH_DefaultDomain_3&hash=item2a3f6bce28

flux £1.90 – for clean solid connections and no dry joints.

Medium-active flux that facilitates soldering of the following elements: copper, silver-plated, zinc-coated and nickel-plated http://www.ebay.co.uk/itm/Electronic-Solder-Flux-Paste-to-Avoid-Dry-Joints-40g-/141490692497?pt=LH_DefaultDomain_3&hash=item20f180a191

heat shrink £4.99 (£0.018 per sleve) - To prevent shorts in the box and protect solder work.Minimum Shrinkage Temp: +70°CFull Shrinkage Temp: +110°C maximumOperating Temperature: -55°C to +125°CTensile strength: 10.4 MpaDielectric strength: 15 kV/mmFlammability: Flame Retardant

Supplied format (round or flat) : Product is supplied flatCutting method: Scissors or sharp knifeManufacture specification: ISO9001Approvals: UL ApprovedTo prevent shorts in the boxhttp://www.ebay.co.uk/itm/280-Pcs-Heat-Shrink-Car-Electrical-Wire-Tubing-Tube-Sleeving-Wrap-Cable-Kit-/400915303115?pt=LH_DefaultDomain_3&hash=item5d586a0acb

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Double sided tape £2.40To secure batteries together

Epoxy resin £2.49 – to secure some of the components used.Epoxy adhesive glue glass wood leather plasticSticks: ceramic, glass, wood, leather, fibreglass,Plastic, paper.....etcQuick setting: 4-6 minutesEpoxy adhesive automatically dispenses into equal partsWith 1 push.Perfect for bonding glass, metal, china, wood and fibreglasswww.amazon.co.uk

Clear polycarbonate palram perspex plastic sheet £1.99 Used for the window on the box (replace the metal box lid)www.ebay.co.uk

Tint film £4.49

Used to give the box a stylish professional look over the windowed part of the box that will replace the lid of the Hammond box.

www.ebay.co.uk

Fire button £3.30

Used to activate, lock and changes modes on the device.

http://www.modmaker.co.uk/Mod-Making-Supplies/Switches/12mm-Green-LED-Metal-Illuminated-Switch-Flat-Raised-Actuator

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total cost

For start up includes tools = £72Each standard box (no custom parts or window) will cost to build = £42 retail price = £57 (£15 profit)Custom boxes will range from - £52 to £150 depending on customer demands.

Pre-assemble

Preparation before swirl painting (done after drilled out holes)

Before we start to build our box we need to do our swirl paint job to give the box a stylish unique professional look. So to do this we need enamel paints (colours picked by customer), we also need some flat primer (no gloss) to spray the box with, and this provides a good surface for the paint to stick to. To protect the box we need some clear coat spray. We will also use some painters tape this will be used for any part of the box the customer does not want pained (can be used for cut out designs on the box as well). We also require to have a container to hold water (this must be big enough to fully submerge the box into the water without touching the bottom or sides of the container. We need to achieve a temperature of 25 degrees C in the water as well so a water heater may be required. We will use borax powder to help the paint float on the top of the water. Pipettes will be used to add little droplets of paint to the water. Finally we use a flat shaped stir stick, this will help us move the paint around and make swirl patterns in the paint.

Swirl painting

1. We take our box without the lid, using painters tape we cover all the inside and any other area’s that we do not want the paint to be on.

2. We will now cover the box with the primer 3. Now fill our container with water and record how much water we are adding.4. Add the water heater and set it to 25 degrees c (normal room temp)5. Once the water is heated to 25 degrees C we add the required amount of borax (ratio = 1

and a half table spoons per 4.5 litres)6. Next we stir the mixture ensuring all the borax has dissolved7. Next we will remove the water heater and start applying our paints to the surface of the

water starting with the darkest colour first.8. Now we take our stir stick and slowly move the paint around till we achieve a good looking

swirl pattern.9. Now we will slowly start applying our box to the paint inserting the box on a angle so we

don’t get any flat sides and slowly move the box from side to side as we submerge the box to collect the paint and get a wavy look to the box.

10. Once the box is fully submerged, take your stick and move all the paint away from the surface of the water once it looks clear we can remove our box from the water.

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11. Now we can see what the box will look like we will now hang the box until it’s fully dry and then protect it using the clear coat.

The swirl paint will look something like this:Image taken from: http://kopics.com/wp-content/uploads/2015/05/Paint-Swirl-Free-Wallpaper-Desktop.jpg.

The build process

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First of all we should look at how to wire this chip to our other components we can do this by looking at the manufactures datasheet.

Image taken from manufactures datasheet found here: http://www.evolvapor.com/datasheet/dna30.pdf

Wiering diagram

As i had no access at this time to scematics i had to draw my diagram using paint.To make things easier for myself i created this wiering diagram.

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Wiring

Because number 16 in the diagram (on board fire switch) is useless to us as where fitting our own switch we will remove the on board switch to save room as the box is quite small we need to make as much room as possible where we can.

Now we can proceed to follow the wiring diagram i created above and solder all the wires as shown i do this by adding flux to the wire and solder then place the wire in the required place on the board and just touch the end of the wire where the connection needs to be made with the tip of the soldering iron and the solder will flow onto the required place of contact and repeat this for each connection on the board.

On the up and down toggle switches there is 4 legs but we only need to so what we will do is cut off 2 of the legs on one side and bend down the other 2 legs so there flat for soldering to and again saving space. Now we will add the positive and negative wires to the buttons by applying flux again and soldering onto each leg (this process is repeated for the up and for the down switch), we now add heat shrink to both legs and heat them up carefully ensuring we don’t burn anything till they have shrunk around each wire this also gives a nice clean look to the build while also protecting the box from short circuits.

Next we will work on the Lipo batteries each rated at 1200mAh and we will connect them together in parallel to get a total of 24000mAh while maintaining the 3.7V, to connect these batteries together in parallel we will take both the positive wires from each battery and connect them together then do the same for the negative wire. First of all where going to use the double sided tape to tape the 2 batteries together, now we will cut off the connectors on the batteries leaving about 1 inch of wire while being very careful not to let the open negative and positive wires connect with each other as this could be very dangerous. Now we need 4 3A fuses connected in parallel to create a 12A fuse. The first positive wire will connect to 2 fuses and the second positive wire will also connect to 2 fuses then on the other side of all the fuses they will all connect together into 1 positive wire making a total of 12A fuse.

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Now we will work on the micro usb charging port for the device, all we need to do here is solder the negative and positive terminals.

Next we will solder the negative wire to the base of our 510 connector and the positive wire to the centre pin and apply heat shrink to both wires.

And finally the firing button has 2 pins all we need to do is choose a pin for negative and one for positive then solder them on and apply the heat shrink.

Clear window

Now using our Clear polycarbonate Perspex plastic sheet we have 2 options

Option 1) place the box directly on top of the Perspex sheep and draw around it with a pen

Option 2) using the dimensions of the box 31mmx93mmx39mm (D*H*W), mark out the measurements on the Perspex sheet and cut it out and smooth off the corners.

Then we will pin point where each screw hole needs to be on the cut out window and drill out the holes required and then counter sync them so the screws sit flush with the window.

Epoxy

With short circuits in mind i will apply a small square of Perspex and Epoxy it to the bottom of the micro USB charging board, and then we will apply more Epoxy to the bottom of the Perspex to attach it to the bottom of our box doing this will also raise the charging port from the very bottom of the case up a few mm and this will further add to the professional looking finish.

Now we will Epoxy the 510 connector and the toggle power up and down buttons to the case.

Double sided tape

Now we will insert the batteries into the bottom of the case using the double sided tape (so they may be removed and replaced if needed)

Then we will take the DNA 30D board and place the wires facing the correct directions as they will go inside the case then using the double sided tape again we will tape the LCD screen directly on top of the DNA board. Now we will place the DNA using double sided tape directly onto the top of the batteries in the middle of the whole box (again this will only be double sided stuck down in the event that the batteries need replacing at any stage).

Final wiring

Now all we need to do is follow this wiring diagram i created and connect all the wires together as at this stage the wires are in 2 half for all the components, it was done like this to make the building process easier for myself. Before soldering all the wires together we need to apply heat shrink to each wire then solder them all then use a heat gun to shrink the heat shrink over each soldered wire.

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extras

These extras are what makes this box completely unique to the user as there is almost 100% no chance anyone will have a box that looks like there’s.

Tint the clear Perspex window any colour the customer requires – to do this we will apply tint film to the Perspex.

Wide range of buttons with led lights or without that customer will be able to choose from (fire button and the power up and down buttons).

Wide range of optional different metal, different colours for the 510 connector cap.

Wade range of colours to pick from for the swirl paint job.

The customer can email patterns or logos that they would like on the back of their box.- to do this we would create a stencil using the painters tape for the logo or pattern they want and apply it to the back of the box prior to doing the swirl paint then we could peal the stencil off.

About the DNA chip

The normal, special operating modes and error messages are shown on the display are shown below.

Taken from the manufactures datasheet: http://www.evolvapor.com/datasheet/dna30.pdf

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Reason for picking 20 gauge wire

(image from manufactures datasheet: http://www.evolvapor.com/datasheet/dna30.pdf)

As you can see in the chart above the maximum wire size is 20 gauges wire hence why all the wires in this build are 20 gauges, this is to make the device more cost efficient so we don’t have to purchase multiple sizes of wire.

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Reason for building the box

Reasons for me designing this box are:

1) I have noticed a large number of people complaining about there batteries dying too quickly.2) People also like devices to be different and unique to themselves.3) I wanted to design E-cigarette that can comfortably sit in your pocket.4) I have also noticed some very expensive e cigarettes on the market and wanted to build

something with all the features people want at a low cost while maintaining the stylish professional look.

5) There is a high demand for high powered e cig devices.6) The market for electronic cigarette devices it growing at a rapid rate.7) I wanted to design a box with a micro USB charger so the box can be used while being

charged unlike other e-cigarettes.8) Most people want a device capable of producing a lot of flavour.9) People like to adjust their voltage/wattage on their devices.10) I wanted to make a device with safety features as a lot of e-cigarettes on the market are not

safe.11) People like the ability to use any type of atomiser on their device.12) Support for coils with less than 1.0 Ohms.13) Wanted to design a simple device to use to make it user friendly.14) Completely customisable to how the customer would like the product.15) Large companies are investing in ecig products.

marketing aimed at smokers Will be presented as:

• A healthier and safer source of nicotine than traditional cigarettes.

• Good for cutting down, quitting or switching from traditional cigarettes.

• Suitable for use in situations where the smoke free legislation applies; and without releasing harmful second-hand smoke.

• tasting similar to tobacco, but cleaner and more fragrant.

• Cheaper than traditional cigarettes, backed by promotional pricing for starter kits to incentivise trials by committed smokers and pricing offers aimed at retailers to keep stock outlays to a minimum.

•Promotional pieces such as news-generating surveys, competitions, press releases, adverts and paid-for advertorials in the popular and trade press are common tactics.

•One brand sponsored a free public lecture on e-cigarettes (with refreshments) at a university to ‘explain what they are, how they work, whether they help people stop smoking and whether they are safe’ (Newham Recorder).

•Television adverts for e-cigarettes also target the committed smoker who is considering quitting.

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•Overall for this consumer group, e-cigarettes are positioned by the independent companies as a normalised necessity – the ultimate, socially acceptable, smoking alternative for someone addicted to nicotine.

Marketing aimed towards current e-cig users

Longer lasting batteries times Compatible with all atomisers Safe to sub ohm on User friendly device Highly customizable Made Unique to every user Variable voltage/wattage Lcd screen display Stylish without the high price tag

Company logo design

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CAD drawings

Right hand ride of box

top of box

all other sides remain untouched.